W Shape 2 And 3 Waves Highway Guardrail Steel Plate Roll Forming Machine Cold Rolling Mill

W Shape 2 And 3 Waves Highway Guardrail Steel Plate Roll Forming Machine Cold Rolling Mill

Product Introduction:

The Corrugated Plate Roll Forming Production Line is designed to achieve a fully continuous and integrated manufacturing process, transforming raw sheet material into finished products through multiple uninterrupted processing stages. The complete production sequence—including decoiling, leveling, punching, roll forming, and cutting—is executed automatically within a single production line. This integrated design ensures consistent product appearance, accurate hole positioning, and simplified installation. Featuring high-speed operation, in-line punching, and continuous roll forming, the system significantly improves manufacturing efficiency while reducing labor requirements and production costs.

Product configuration:

Note: when order is confirmed, both partiesneed to sign the profile drawing , punch hole drawing and arch part drawing together.

Production process:

Decoilre- leveler - material loop—servo feeder—puncher—material loop-- main roll former—cutter - workpiece outside

Material Loop (2 Sets)

Function: The first material loop is designed to synchronize and regulate the operating speed between the buffer traction leveling unit and the servo leveling feeder, ensuring stable material flow. The second material loop coordinates speed matching between the punching section and the roll forming unit, maintaining continuous strip tension and ensuring smooth, reliable operation throughout the entire production line.

Structure: The material storage system is divided into two independent sections, each comprising arc-shaped roller assemblies and supporting structures. Four sets of arc-shaped guide rollers are installed on both sides of the two storage pits. Each roller assembly consists of a curved support frame and multiple flexible guide rollers. The roller surfaces are hard chrome plated to provide excellent wear resistance, corrosion protection, and extended service life. Photoelectric sensing devices are installed within the storage pits to continuously monitor the strip position and automatically regulate material accumulation, enabling precise speed synchronization and stable coordination between each processing station across the production line.

Servo Leveling and Feeding Unit (1 Set)

This unit is positioned at the front end of the multi-station punching press and is directly integrated with the punch press base, providing stable material feeding and precise positioning for subsequent punching operations. The leveling section adopts a five-roll configuration, consisting of two upper leveling rolls and three lower leveling rolls. The upper rolls are hydraulically actuated and can be adjusted downward to achieve optimum leveling performance for various material specifications. In addition to their leveling function, the upper rolls also serve as servo-driven feeding rolls, ensuring accurate and continuous delivery of the material into the punching station.

The servo feeding mechanism is driven by a high-performance servo motor, providing precise feed length control and excellent repeatability. Multiple feeding programs and processing parameters can be preset, stored, and recalled through the control system. Based on the programmed data, the servo feeder automatically advances the material to the specified feed length for each punching cycle, ensuring consistent positioning accuracy, stable production performance, and high processing efficiency.

Multi-Station Punching Unit (1 Set)

Function: The unit is designed to complete the punching of fifteen Ø25 mm holes on the workpiece in a single processing cycle, ensuring high productivity, excellent positional accuracy, and consistent punching quality.

Structure: The punching system adopts a four-column hydraulic press structure, offering a cost-effective, robust, and highly reliable solution for high-volume production. Specifically engineered for multi-station punching operations, the hydraulic system incorporates a hydraulic pump-and-accumulator drive system together with a dedicated hydraulic control circuit. This configuration provides rapid punching speed, low operating noise, stable pressure output, and dependable operational performance. An integrated cooling and heat dissipation system effectively controls hydraulic oil temperature, ensuring reliable continuous operation during extended production cycles. The hydraulic design has been extensively validated through long-term application in multiple industrial production lines, demonstrating outstanding stability and durability.

Punching Capacity: 500 Tons

Main roll former 1 set

Structure: The roll forming unit adopts an independent housing-frame structure. Power is transmitted through a motor and reducer system, utilizing reduction gearboxes and couplings mounted separately on the forming base and transmission base. The lower shaft serves as the primary driving shaft, while synchronization gears are installed between the upper and lower shafts when required. The main transmission system incorporates a secondary reduction gearbox to ensure stable and efficient power delivery.

The forming rollers are designed using professional engineering software. The roller material is manufactured from high-quality Cr12 tool steel and undergoes heat treatment to achieve a hardness of HRC 58–62. Selected forming rollers are manufactured from Cr12MoV material to further enhance mechanical properties, wear resistance, and service life. All roller surfaces are precision-machined and polished after finishing, ensuring high dimensional accuracy, superior surface quality, and extended operational lifespan. The exterior of the housing frame is equipped with two types of adjustment nuts: left-hand threaded nuts for the lower shaft and right-hand threaded nuts for the upper shaft, allowing convenient and precise roller adjustment.